FUEL CELL SYSTEM
A fuel cell system includes a fuel pre-heater, a fuel cell stack and a cooling circuit which is arranged to implement a Rankine cycle and includes a condenser. The fuel pre-heater is arranged to heat a flow of liquid hydrogen provided to an input thereof to provide a flow of gaseous hydrogen. The system further includes a conveying apparatus arranged to convey the gaseous hydrogen to a fuel input of the fuel cell stack such that the gaseous hydrogen is in thermal contact with coolant fluid in the condenser. The size and mass of the condenser may thereby be reduced. The pre-heater is arranged to heat coolant fluid within the cooling circuit, thereby increasing the efficiency of the Rankine cycle.
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The invention relates to fuel cell systems.
BACKGROUNDFuel cell systems which use hydrogen as a fuel are of interest for use in transport applications, including aviation, as they do not produce carbon dioxide at the point of use. Storage of hydrogen in liquid form, prior to its use in gaseous form, is of particular interest due to the greater volumetric energy density of liquid hydrogen (˜8.5 MJ/I) compared to that of gaseous hydrogen (˜2.7 MJ/l at 300 bar). It is known to vaporise liquid hydrogen by use of a pre-heating element to produce a flow of gaseous hydrogen (e.g. published patent applications CN112599815A, CN110597504A, JPS5026419U). In addition to vaporising liquid hydrogen, a fuel cell system using liquid hydrogen is also required to condition the temperature of the resulting gaseous hydrogen, prior to its input to a fuel cell stack of the fuel cell system. It is known to heat gaseous hydrogen, prior to input thereof to a fuel cell stack, by means of heat exchange with cooling fluid in a cooling loop associated with the stack, thereby utilising waste heat from the stack (e.g. published patent applications KR20130070161A, CN112599815A and CN110957504A). Some types of fuel cell stack have relatively low operating temperatures. For example a polymer electrolyte (proton exchange) membrane (PEM) stack typically has an operating temperature of less than around 90° C. If the cooling loop for such a stack implements a Rankine cycle, relatively low levels of power are recovered with low efficiency. Furthermore, a condenser within the cooling loop which is needed to implement a Rankine cycle can have significant size and mass, making the system unattractive for vehicle propulsion, especially aircraft propulsion. The use of cold gaseous hydrogen resulting from boil-off from a reservoir of liquid hydrogen to condense vaporised coolant fluid within a Rankine-type cooling circuit for a fuel cell stack is described by Marandi et al, in the paper “Exergy and exergoeconomic comparison between multiple novel combined systems based on proton exchange membrane fuel cells integrated with organic Rankine cycles, and hydrogen boil-off gas subsystem”, Energy Conversion & Management 244 (2021), article 114532.
BRIEF SUMMARYA first aspect of the invention provides a fuel cell system comprising a fuel pre-heater, a fuel cell stack and a cooling circuit arranged to cool the fuel cell stack, the fuel pre-heater being arranged to heat a flow of liquid hydrogen provided to an input thereof to provide a flow of gaseous hydrogen at an output thereof, the fuel cell system further comprising conveying means arranged to convey gaseous hydrogen from the output of the fuel pre-heater to a fuel input of the fuel cell stack and wherein the conveying means and the cooling circuit are arranged such that coolant fluid within the cooling circuit is in thermal contact with gaseous hydrogen within the conveying means during operation of the fuel cell system, characterised in that (a) the cooling circuit implements a Rankine cycle and includes a condenser arranged to condense gaseous coolant within the cooling circuit; (b) the condenser and the conveying means are arranged such that coolant fluid within the condenser is in thermal contact with gaseous hydrogen within the conveying means during operation of the fuel cell system; and (c) the pre-heater is arranged to heat coolant fluid within the cooling circuit. In operation of a fuel cell system of the invention, heat within coolant fluid within the condenser passes into gaseous hydrogen en route from the pre-heater to the fuel cell stack, thus assisting both in cooling the fuel cell stack and in heating the gaseous hydrogen to a temperature suitable for input to the fuel cell stack. The temperature of the gaseous hydrogen output by the pre-heater may be arranged such that the temperature of the gaseous hydrogen as it enters the fuel cell stack (after heat-exchange with coolant fluid in the condenser) is high enough to allow efficient reaction within the stack.
The size and weight of the condenser may be reduced compared to a case where a cooling circuit implementing a Rankine cycle comprises a condenser, and all heat from the condenser is lost to ambient air. The pre-heater is arranged to heat coolant fluid within the cooling circuit, thereby increasing the efficiency with which heat is converted to mechanical work by the Rankine cycle.
The pre-heater may be arranged to combust a portion of the flow of liquid hydrogen provided to the input of the pre-heater in order to generate heat to vaporise, or vaporise and heat, the remainder of the flow. Alternatively, the pre-heater may be arranged to combust at least a portion of hydrogen output from the fuel cell stack in order to generate heat to vaporise, or vaporise and heat, the flow of liquid hydrogen provided to the input of the pre-heater.
The fuel cell system may comprise a turbocharger, the turbocharger comprising a compressor arranged to be driven by a turbine in operation of the fuel cell system and to provide compressed air to an input of the fuel cell stack, the fuel cell system being arranged such that combustion products produced by the pre-heater are provided to the turbine.
A second aspect of the invention provides a propulsion system comprising a fuel cell system according to the first aspect of the invention and an electric propulsor arranged to receive electrical power from the fuel cell system and to provide propulsive thrust using the electrical power.
A third aspect of the invention provides an aircraft comprising a propulsion system according to the second aspect of the invention.
Embodiments of the invention are described below by way of example only and with reference to the accompanying drawings in which:
Referring to
In operation of the fuel cell system 200, air enters an air intake 213 and passes through an air filter 215 to the compressor 224 of the turbocharger 217. Compressed air output from the compressor 224 passes through the heat exchanger 258, thereby cooling the compressed air, and the humidifier 226, and is provided to the input 208 of the cathode side 204 of the PEM fuel cell stack 202. Cathode exhaust comprising air and water vapour exits the cathode side 204 at output 210; water vapour in the cathode exhaust is recovered by the humidifier 226 and the remaining cathode exhaust is delivered the turbine 222 of the turbocharger 217. A flow of liquid hydrogen (LH2) fuel from a fuel store (not shown) is input to the system 200 at a fuel input 280 and passes to the fuel pre-heater 227. Air is input to the pre-heater 227 via an air input 282. A portion of the flow of liquid hydrogen is combusted in the pre-heater 227 producing heat which converts the remainder of the flow into gaseous hydrogen (GH2) which is provided to the input 212 of the anode side 206 of the PEM fuel cell stack 202 via an ejector 230. The gaseous hydrogen output from the pre-heater 227 is conveyed to the ejector 230 by conveying means 228 on a path via the coolant/air heat exchanger 253, such that the gaseous hydrogen within the conveying means 228 is in thermal contact with coolant fluid within the heat exchanger 253. Heat therefore passes from the coolant fluid within the heat exchanger 253 to the gaseous hydrogen within the conveying means 228 passing from the pre-heater 227 to the ejector 230. The heat exchanger 253 is smaller and lighter than the heat exchanger 153 of the fuel cell system 100 of
DC electrical power is provided at an electrical output 220 of the PEM fuel cell stack 202 and to a low voltage bus 244 via a DC/DC converter 241 and an inverter 242. The low voltage bus 244 provides power to the electric motor 246. Electrical power may be provided to an electric propulsor (not shown), for example, via an electrical output 248 of the DC/DC converter 241.
The pre-heater 227 is arranged such that the temperature of gaseous hydrogen entering the conveying means 228 is sufficient to achieve an adequate reaction rate within the fuel cell stack 202, even if minimal additional heat passes into the gaseous hydrogen from cooling fluid within the cooling circuit 250, as may be the case during start-up of the system 200, or when the electrical output power of the stack 202 is low.
In operation of the fuel cell system 300, flows of air and liquid hydrogen (LH2) fuel are input to a pre-heater 327 (e.g. a catalytic burner) at fuel and air inputs 380, 382 respectively. A portion of the flow of liquid hydrogen fuel is combusted by the pre-heater 327 to convert the remaining flow to gaseous hydrogen (GH2) which is conveyed by conveying means 328 to input 312 of anode 306 via heat exchanger 364 and ejector 330 on a path whereby the gaseous hydrogen within the conveying means 328 is in thermal contact with coolant fluid within condenser 351. The size and weight of the condenser 351 are reduced compared to those of the heat exchanger 153 of the fuel cell system 100 of
The fuel cell system 300 further comprises low- and high-voltage DC/DC converters 343, 345 respectively and a low voltage bus 344.
The thermodynamic efficiency ηth with which net work Wnet is extracted by the Rankine cycle is
where Qin is the heat input to the coolant fluid by the PEM fuel cell stack 102 plus the heat input to the coolant fluid by the heater 357, and Qout is the heat output from the condenser 351. The net work Wnet is the difference between the work extracted by the turbine 358 and the work carried out by the pump 354. If hi is the enthalpy at position i, where i=1, 2, 3 or 4, the thermodynamic efficiency ηth is given by
The thermodynamic efficiency with which work is extracted by the turbine 358 is therefore also increased by the presence of the heater 357 (in addition to an increase in the absolute amount of work extracted) since the enthalpy h3 of the coolant fluid at position 3 (immediately before the turbine 358) is greater than h3 in the absence of the heater 357, so that the value h3−h2 is increased by the heater 357.
The coolant fluid within the cooling circuit 650 is water. The cooling circuit 650 is arranged such that the water is in the form of steam between heater 657 and condenser 651 and in liquid form between the condenser 651 and coolant input 616 of PEM fuel cell stack 602. Liquid water entering the PEM fuel cell stack 602 at coolant input 616 is heated by waste heat from the stack 602 and wholly or partially converted to steam. Any remaining liquid water output at coolant output 618, together with water from cooling branch 660, is converted to steam by heater 657. Steam out from the heater 657 is delivered to turbine 658 comprised in cooling circuit 650.
Any of the pre-heaters 227, 327, 427, 557, 657 of the fuel cell systems 200, 300, 400, 500, 600 respectively may allow the rate at which hydrogen is combusted therein to be adjusted, thus allowing the temperature of gaseous hydrogen leaving the pre-heater to be adjusted.
Claims
1-9. (canceled)
10. A fuel cell system comprising a fuel pre-heater, a fuel cell stack and a cooling circuit arranged to cool the fuel cell stack, the fuel pre-heater being arranged to heat a flow of liquid hydrogen provided to an input thereof to provide a flow of gaseous hydrogen at an output thereof, the fuel cell system further comprising conveying means arranged to convey gaseous hydrogen from the output of the fuel pre-heater to a fuel input of the fuel cell stack and wherein the conveying means and the cooling circuit are arranged such that coolant fluid within the cooling circuit is in thermal contact with gaseous hydrogen within the conveying means during operation of the fuel cell system, wherein
- (a) the cooling circuit implements a Rankine cycle and includes a condenser arranged to condense gaseous coolant within the cooling circuit;
- (b) the condenser and the conveying means are arranged such that coolant fluid within the condenser is in thermal contact with gaseous hydrogen within the conveying means during operation of the fuel cell system; and
- (c) the pre-heater is arranged to heat coolant fluid within the cooling circuit.
11. The fuel cell system according to claim 10 wherein the pre-heater is arranged to combust a portion of the flow of liquid hydrogen provided to the input thereof in order to generate heat to vaporise, or vaporise and heat, the remainder of the flow.
12. The fuel cell system according to claim 10 wherein the pre-heater is arranged to combust at least a portion of hydrogen output from the fuel cell stack in order to generate heat to vaporise, or vaporise and heat, the flow of liquid hydrogen provided to the input of the pre-heater.
13. The fuel cell system according to claim 11 and further comprising a turbocharger, the turbocharger comprising a compressor arranged to be driven by a turbine in operation of the fuel cell system, and wherein the compressor is arranged to provide compressed air to an input of the fuel cell stack and the fuel cell system is arranged such that combustion products produced by the pre-heater are provided to the turbine.
14. A propulsion system comprising a fuel cell system according to claim and an electric propulsor arranged to receive electrical power from the fuel cell system and to provide propulsive thrust using the electrical power.
15. An aircraft comprising a propulsion system according to claim 14.
16. The fuel cell system according to claim 12 and further comprising a turbocharger, the turbocharger comprising a compressor arranged to be driven by a turbine in operation of the fuel cell system, and wherein the compressor is arranged to provide compressed air to an input of the fuel cell stack and the fuel cell system is arranged such that combustion products produced by the pre-heater are provided to the turbine.
17. A propulsion system comprising a fuel cell system according to claim 11 and an electric propulsor arranged to receive electrical power from the fuel cell system and to provide propulsive thrust using the electrical power.
18. A propulsion system comprising a fuel cell system according to claim 12 and an electric propulsor arranged to receive electrical power from the fuel cell system and to provide propulsive thrust using the electrical power.
19. A propulsion system comprising a fuel cell system according to claim 13 and an electric propulsor arranged to receive electrical power from the fuel cell system and to provide propulsive thrust using the electrical power.
20. A propulsion system comprising a fuel cell system according to claim 16 and an electric propulsor arranged to receive electrical power from the fuel cell system and to provide propulsive thrust using the electrical power.
21. An aircraft comprising a propulsion system according to claim 17.
22. An aircraft comprising a propulsion system according to claim 18.
23. An aircraft comprising a propulsion system according to claim 19.
24. An aircraft comprising a propulsion system according to claim 20.
Type: Application
Filed: Oct 4, 2022
Publication Date: Nov 14, 2024
Applicant: ROLLS-ROYCE plc (London)
Inventors: Chloe PALMER (Derby), Jacopo TACCONI (Derby)
Application Number: 18/701,722